Apprenticeship Curriculum Standard. Level 1 and 2. Trade Code: 456P

Transcription

1 Apprenticeship Curriculum Standard Pressure Systems Welder Level 1 and 2 Trade Code: 456P Date: 2010

2 Please Note: Apprenticeship Training and Curriculum Standards were developed by the Ministry of Training, Colleges and Universities (MTCU). As of April 8 th, 2013, the Ontario College of Trades (College) has become responsible for the development and maintenance of these standards. The College is carrying over existing standards without any changes. However, because the Apprenticeship Training and Curriculum Standards documents were developed under either the Trades Qualification and Apprenticeship Act (TQAA) or the Apprenticeship and Certification Act, 1998 (ACA), the definitions contained in these documents may no longer be accurate and may not be reflective of the Ontario College of Trades and Apprenticeship Act, 2009 (OCTAA) as the new trades legislation in the province. The College will update these definitions in the future. Meanwhile, please refer to the College s website ( for the most accurate and up-to-date information about the College. For information on OCTAA and its regulations, please visit:

3 Pressure Systems Welder TABLE OF CONTENTS Introduction...1 Level 1 Program Summary of Reportable Subjects...2 S0771 Welding Theory...3 S Welding Safety...4 S Shielded Metal Arc Welding...6 S Gas Tungsten Arc Welding...8 S Gas Shielded Semi-Automatic Arc Welding...10 S Weld Quality, Inspection and Testing...13 S0772 Shielded Metal Arc Welding (SMAW)...15 S Fillet Welds with SMAW on Mild Steel...16 S Groove Weld in all Positions with SMAW...18 S Perform SMAW Welds for Destructive Testing...19 S0773 Gas Tungsten Arc Welding (GTAW)...20 S Set-Up Equipment for GTAW on Mild and Stainless Steels 21 S Perform Mild Steel Welds Using the GTAW Process...22 S Perform Stainless Steel Welds Using the GTAW Process.23 S0774 Gas Shielded Semi-Automatic Welding...24 S Fillet Welds with Gas Metal Arc Welding (GMAW)...25 S Groove Welds with Gas Metal Arc Welding (GMAW)...27 S Pulsed Arc Gas Metal Arc Welding (GMAW-P)...29 S Fillet Welds with Flux Cored Arc Welding (FCAW)...30 S Groove Welds with Flux Cored Arc Welding (FCAW)...32

4 Pressure Systems Welder TABLE OF CONTENTS Level 2 Program Summary of Reportable Subjects...35 S0775 Codes for Pressure Welding...36 S ASME Boiler and Pressure Vessel Code...37 S Material Specifications...38 S Product Specifications...39 S Inspection Specifications...40 S0776 Manual Pressure Welding...41 S Cutting and Preparation...42 S Fit-Up and Assembly...44 S Shielded Metal Arc Welding (SMAW)...46 S Gas Tungsten Arc Welding (GTAW)...47 S0777 Semi-Automatic Pressure Welding...49 S Gas Metal Arc Welding (GMAW)...50 S Flux Cored Arc Welding (FCAW)...52 S0778 Pressure Welding Procedures and Qualification...54 S Welding Procedure Specifications...55 S Procedure Qualification Records...57 S Welding Performance Qualification...58 S0779 Specialized Pressure Welding Techniques...61 S Braze Pressure Systems...62 S Locate Weld Defects...64 S Remove Weld Defects and Prepare For Re-welding...66 S Mirror Welding...68 S Window Welding...70

5 Pressure Systems Welder RECOMMENDED MINIMUM EQUIPMENT: Power Sources and Equipment SMAW (CC) (AC/DC) power source and equipment GTAW (CC), AC/DC, high frequency, square wave, pulsed power source and equipment, water-cooled torch, foot controller Plasma arc cutting power source and equipment Air-Carbon-Arc-Gouging power source and equipment Oxy-fuel-gas manual cutting equipment Oxy-fuel-gas semi-automatic cutting equipment Oxy-fuel-gas-heating torch and equipment Approved electrode storage oven Compressed air supply ( psi) Quantity 1 per apprentice 1 per 5 apprentices 1 per 5 apprentices 1 per 5 apprentices 1 per apprentice 1 per 5 apprentices 1 per 5 apprentices 1 per shop 1 per shop Fabrication Machines (1 each per shop) Band saw Nibbler Ironworker Pedestal grinders Cut-off abrasive wheel saw Weld-bevel preparation equipment for plate and pipe Weld-coupon bending apparatus Approved smoke extraction/air make-up unit Welding and fabricating shops must be well lit, appropriately heated and ventilated

6 Basic Hand Tools and Equipment Adjustable wrenches (various sizes) Allen wrenches (metric and imperial) Bench and pipe vice "C" clamps (various sizes) Chalk-line Cold chisels (various sizes) Electric extension cords Files (flat, half-round, rat-tail, bastard) Friction lighter Grinders, grinding and sanding disks (for carbon steel, aluminum and stainless steel) Hacksaw Hammers (chipping, ball peen) Hand shears Layout table Magnets Metal markers Pipe clamps Pipe cutter Pipe wrenches Root opening spacing tools (1 per apprentice) Pliers (needle nose, slip joint) Positioners Pry bars Punches Screwdrivers (slot, Phillips, Robertson, various sizes) Scribers Snips (heavy duty sheet metal cutting) Soapstone markers Socket sets (metric and imperial) Temperature indicating crayons Tip cleaners Toolboxes Tungsten sharpening grinders Vice grips (various sizes and types) Wire brushes (for carbon steel, aluminum and stainless steel) Wire cutters Work bench Wrench sets (open and closed ends, both metric and imperial)

7 Measuring Tools Drafting equip Combination square Fillet gauges Spirit level Vernier caliper Square Straight edge Scriber Micrometer Tape measure (1 per apprentice) Safety Equipment Earplugs and muffs Face shields Fire blankets Fire extinguishers Goggles Leather aprons (1 per apprentice) Leather gloves Leather jackets Masks (particle, vapour) Respirators Safety glasses

8 INTRODUCTION Pressure Systems Welder This new curriculum standard for the Pressure Systems Welder (456P) trade program is based upon the on-the-job performance objectives, located in the industry-approved training standard. The curriculum is organized into two levels of reportable subjects. The Program Summary of Reportable Subjects chart summarizes the training hours for each reportable subject. The curriculum identifies only the learning that takes place off-the-job. The inschool program focuses primarily on the theoretical knowledge and the essential skills required to support the performance objectives of the Apprenticeship Training Standard. Regular evaluations of the apprentice s knowledge and skills are conducted throughout training to ensure that all apprentices have achieved the learning outcomes identified in the curriculum standard. Employers/Sponsors are expected to extend the apprentice s knowledge and skills through practical training on the work site. It is not the intent of the in-school curriculum to perfect on-the-job skills. The practical portion of the in-school program is used to reinforce theoretical knowledge. The practical welding skill training specified in this curriculum should be complemented with on-the-job skills practice. For easy reference, a time allocation has been included for each reportable subject, unit and topics, along with a breakdown of theory and application in the delivery of the performance objectives. The curriculum standard has been designed to give the instructor opportunity for flexibility and innovation without significant departures from content. Since the scope of the prescribed curriculum standard is quite extensive, the apprentice will be expected to reinforce the acquired knowledge through regular independent out-of-classroom assignments. Level 1 of this curriculum is intended for those apprentices who do not have a Certificate of Apprenticeship in the 456A Welder trade and all-position certification in the SMAW, GTAW and GMAW or FCAW welding processes. 456P Apprentices who do not have those qualifications must complete Level 1 or successfully complete the Exemption Test and submit the same welding qualification certification. 1

9 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 1 Pressure Systems Welder Level 1 PROGRAM SUMMARY OF REPORTABLE SUBJECTS Subject Number Reportable Subject Hours Total Hours Theory Hours Practical S0771 Welding Theory S0772 Shielded Metal Arc Welding S0773 Gas Tungsten Arc Welding S0774 Gas Shielded Semi-Automatic Arc Welding Total

10 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 1 Subject Number: Reportable Title: S0771 WELDING THEORY Duration in Hours: Total Hours: 33 Theory: 33 Practical: 0 Prerequisites: None Content: S Welding Safety [3/0] S Shielded Metal Arc Welding [7/0] S Gas Tungsten Arc Welding [7/0] S Gas Shielded Semi-Automatic Welding [7/0] S Weld Quality, Inspection and Testing [9/0] Evaluation & Testing: Assignments related to theory and appropriate application skills Minimum of one mid-term test during the term Final exam at end of term Periodic quizzes Mark Distribution: Theory Practical Projects Notebook & Final Testing Testing Organizational Skills Assessment 60% 0% 15% 10% 15% Instructional and Delivery Strategies: Lecture and assignment work. Reference Materials Ontario Occupational Health and Safety Act Alberta ILM Welder Apprenticeship Modules 3

11 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 1 S WELDING SAFETY Total Hours: 3 Theory: 3 Practical: 0 Cross-Reference to Training Standard: , , , , , , , General Learning Outcome: Upon successful completion, the apprentice is able to: Describe the safe work practices considering, Industrial Safety Acts and potential workplace hazards in accordance with government safety regulations, manufacturer s recommendations and approved industry standards. Learning Outcomes: 1.1 Describe the necessary personal protection against common shop and construction hazards. [1/0] electrical shock - water and electricity - good ground connection - cable connection fumes and gases - ozone and nitrogen dioxide heat and burns - spatter - fire - sparks appropriate clothing radiation - ultraviolet, infrared and visible light - appropriate helmet and filter plates noise fall protection falling objects 1.2 Explain the safe use and operation of equipment. [1/0] storage and handling of compressed gas cylinders power tools hand tools fabricating equipment 4

12 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 1 lockout scaffolding safety harness elevated platforms 1.3 Identify potential workplace hazards. [1/0] confined spaces oxygen depletion moving equipment tripping hazards emergency responses incident reports near misses fires 5

13 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 1 S SHIELDED METAL ARC WELDING Total Hours: 7 Theory: 7 hours Practical: 0 hours Cross-Reference to Training Standard Performance Objectives: , , , , , , , General Learning Outcome: Upon successful completion, the apprentice is able to: Describe the fundamentals of the SMAW process in accordance with government safety regulations, manufacturer s recommendations and approved industry standards. Learning Outcomes and Content: 2.1 Define the fundamentals of the SMAW process. [2/0] method of melting, freezing and fusion arc characteristics arc length and effect on voltage penetration travel speed and effects of too fast or too slow travel speed weld contamination protection electrode angle 2.2 Describe the equipment requirements for the SMAW process. [2/0] power sources - transformers - rectifiers - inverters - generators power source controls - amperage - duty cycle - voltage - current type and polarity - arc force electrode holders welding cables - cable size and condition - connectors 6

14 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 1 - relationship to required amperage - work lead - completion of welding circuit - clamps in good repair 2.3 Describe the construction and characteristics of SMAW electrodes. [1.5/0] basic construction features - core wire - flux covering shielding manufacturing methods of welding electrodes - electrode concentricity functions of the flux coating flux coating base material - low hydrogen (basic) - cellulose - iron powder chemical properties and alloying elements classification of SMAW electrodes, CSA and AWS - mild steel - low alloy - stainless steel - meaning of each letter and numerical group - imperial and metric versions storage and handling - re-baking and electrode conditioning - storage temperatures 2.4 Describe the SMAW procedure variables and their effect on quality and productivity. [1.5/0] primary variables (conducted prior to welding) - joint design and fit-up - consumables - current type and polarity - amperage - electrode size secondary variables (conducted during welding) - travel speed - arc length - electrode and work angles - weaving or stringer multiple passes 7

15 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 1 S GAS TUNGSTEN ARC WELDING (GTAW) Total Hours: 7 Theory: 7 Practical: 0 Cross-Reference to Training Standard: , , , , , , , , , General Learning Outcome: Upon successful completion, the apprentice is able to: Explain the of set-up and operation of the GTAW process and selection of GTAW consumables in accordance with government safety regulations, manufacturer s recommendations and approved industry standards. Learning Outcomes and Content: 3.1 Define the fundamentals of the GTAW process. [2/0] non-consumable tungsten electrode gas shielding of weld advantages of the GTAW process - no spatter - all position capable - high quality welds - concentrated high-temperature arc - wide variety of applications and alloys limitations of the GTAW process - deposition rates - pre-cleaning required 3.2 Explain the safety concerns applicable to the GTAW process. [1/0] arc radiation air quality fumes and gases - oxygen depletion high frequency current thorium high pressure cylinders 3.3 Describe the required equipment and components for the GTAW process. [1/0] 8

16 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 1 fundamentals and characteristics of the constant current power source - welding current type and polarity - high frequency (HF) circuit - contactor and current control methods - manual and remote controls - torch thumbwheel shielding gas supply system - cylinders or bulk systems - regulator and flow meter torches - air and water cooled - amperage rating - collet and body - nozzle - gas lens coolant circulators 3.4 Explain the set-up and control of the process variables for the GTAW process. [3/0] shielding gas type - flow rate (imperial and metric) - backing gas and purging filler material - type (alloy) and classification - size tungsten electrode - type and grade - size - conditioning and contamination control nozzle configurations and sizes current type and polarity amperage adjustment arc initiation methods - scratch start - lift start - high frequency start torch and filler rod angles arc length travel speed filler rod addition method 9

17 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 1 S GAS SHIELDED SEMI-AUTOMATIC WELDING PROCESSES Total Hours: 7 Theory: 7 Practical: 0 Cross-Reference to Training Standard Performance Objectives: , , , , , , General Learning Outcome: Upon successful completion, the apprentice is able to: Describe the fundamentals, construction features and consumables of the Gas Metal Arc Welding (GMAW) and Flux Cored Arc Welding (FCAW) processes in accordance with government safety regulations, manufacturer s recommendations and approved industry standards. Learning Outcomes and Content: 4.1 Define the fundamentals of the GMAW process. [1/0] modes of metal transfer - short-circuiting transfer - spray arc transfer - pulsed gas shielding - purpose - argon - CO 2 - mixed gases 4.2 Define the fundamentals of the FCAW process. [1/0] process applications, benefits and limitations weld puddle shielding - self shielded FCAW wires - gas shielded FCAW wires 4.3 Explain the function of the components of the GMAW and FCAW process. [1/0] fundamentals and characteristics of the Constant Voltage power source self- correcting arc gap wire feeders - spool guns - push type 10

18 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 1 - push-pull type drive rolls liners gas diffusers contact tips / tubes nozzles water cooled guns 4.4 Explain the selection and characteristics of consumables necessary for GMAW short-circuit transfer and spray-arc transfer. [1/0] optimal wire type and diameter filler metal classification system - low alloy - steels - stainless steels types and sizes purpose of copper plating vs copper free shielding gas - types - flow rate 4.5 Describe the procedure variables for GMAW and their affect on quality and productivity. [1.5/0] primary variables (conducted prior to welding) - joint design and fit-up - wire type and diameter - shielding gas - current type and polarity - wire feed speed and amperage - voltage secondary variables (conducted during welding) - travel speed - contact tip to work distance - work and gun angles - multi-passes - weaving 4.6 Describe the fundamentals of the pulsed-arc metal transfer mode of the Gas Metal Arc Welding Pulsed (GMAW-P) process. [1.5/0] advantages and limitations applications power sources requirements wire feeder requirements 11

19 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 1 additional GMAW-P variables - peak current - peak time - background current - background time control of variables - synergic controls - trim controls 12

20 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 1 S WELD QUALITY, INSPECTION AND TESTING Total Hours: 9 Theory: 9 Practical: 0 Cross-Reference to Training Standard: , , , , , , , , , , , , , , General Learning Outcome: Upon successful completion, the apprentice is able to: Describe the features of weld quality, welding discontinuity and welding procedures in accordance with government safety regulations, manufacturer s recommendations and approved industry standards. Explain the function and application of destructive and non-destructive testing methods for welds in accordance with government safety regulations, manufacturer s recommendations and approved industry standards. Learning Outcomes and Content: 5.1 Define welding discontinuities and their effect on weld quality. [1/0] types of welding discontinuities weld quality intended function of a weld applicable specification acceptance criteria of a weld acceptable discontinuities unacceptable discontinuities 5.2 Explain the types and causes of dimensional and / or geometric discontinuities. [2/0] fillet weld leg throat dimension measurement causes of and significance of insufficient leg length or throat dimension incorrect weld shape - convexity - concavity excess reinforcement 5.3 Identify the types and causes of structural soundness discontinuities. [2/0] cracks 13

21 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 1 inclusions porosity lack of fusion incomplete penetration undercut overlap 5.4 Define procedures for correction of defective weld quality. [1/0] defect excavation procedures inspection of cavity prior to weld repair weld repair procedures 5.5 Explain the function and application of mechanical test methods. [1/0] bend testing - face and root - side 5.6 Explain the function and application of non-destructive examination methods. [2/0] visual inspection method per applicable specifications gauges pre-weld preparation penetrant testing magnetic particle testing radiography ultrasonic testing 14

22 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 1 Subject Number: Reportable Subject: S0772 SHIELDED METAL ARC WELDING (SMAW) Total Hours: 66 Theory: 2 Practical: 64 Prerequisites: None Contents: S Fillet Weld with SMAW on Mild Steel [2/18] S Groove Weld in all Positions with SMAW [0/33] S Perform SMAW Welds for Destructive Testing [0/13] Evaluation & Testing: Practical projects related to the welding process procedure and position. Unit practical tests evaluated in accordance with applicable industrial weld quality acceptance criteria. Mark Distribution: Theory Practical Projects Notebook & Final Testing Testing Organizational Skills Assessment 0% 30% 70% 0% 0% Instructional and Delivery Strategies: Teacher-led practical skills training with demonstration and observation in welding shop. Reference Materials: Alberta ILM Welder Apprenticeship Modules 15

23 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 1 S FILLET WELD WITH SMAW ON MILD STEEL Total Hours: 20 Theory: 2 Practical: 18 Cross-Reference to Training Standard: , , , , , , , , General Learning Outcome: Upon successful completion, the apprentice is able to: Perform fillet welding with the SMAW process in accordance with government safety regulations, manufacturer s recommendations and approved industry standards with a focus of meeting or exceeding the testing requirements of the CSA or ASME Codes/Standards regarding weld quality. Learning Outcomes and Content: 1.1 Describe the equipment set-up of the SMAW process. [2/0] power source equipment consumables material technique type of welds 1.2 Set-up and maintain equipment for SMAW applications. [0/2] electrode selection - type and size power source controls - amperage - voltage - current type and polarity electrode holders various types welding cables - cable size and condition - relationship to required amperage - work lead and clamp - completion of welding circuit 16

24 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 1 clamps in good repair work lead locations 1.3 Fillet weld mild steel using the SMAW process. [0/15] stops and restarts filling crater fillet welds - tee joint - lap joint plate structural shapes structural shapes to plate positions - flat (1F) - horizontal (2F) - vertical (3F) - overhead (4F) electrodes - cellulose - basic 1.4 Perform post-weld operations. [0/1] removing all slag removing all spatter methods of cleaning and finishing of completed weld to specifications - wire brushing - filing - grinding - hand tools - power tools measuring weld size to meet specifications visual examination of weld for discontinuities 17

25 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 1 S GROOVE WELD IN ALL POSITIONS WITH SMAW Total Hours: 33 Theory: 0 Practical: 33 Cross-Reference to Training Standard: , , , , , , , , General Learning Outcome: Upon successful completion, the apprentice is able to: Perform groove welding procedures with the SMAW process in accordance with government safety regulations, manufacturer s recommendations and approved industry standards with a focus of meeting or exceeding the testing requirements of the CSA or ASME Codes/Standards regarding weld quality. Learning Outcomes and Content: 2.1 Prepare base metal for groove welding as required by weld symbol and welding procedure. [0/2] type of groove joint welding symbol type of metal backing requirement method of joint preparation joint opening placement of tacks 2.2 Perform groove welding of mild steel using the SMAW process. [0/30] single vee-groove groove test plates with backing using E flat (1G) - horizontal (2G) - vertical (3G) - overhead (4G) 2.3 Perform post-weld operations. [0/1] inspection of welds - non-destructive test methods - destructive test methods 18

26 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 1 S PERFORM SMAW WELDS FOR DESTRUCTIVE TESTING Total Hours: 13 Theory: 0 Practical: 13 Cross-Reference to Training Standard: , , , , , , , , General Learning Outcome: Upon successful completion, the apprentice is able to: Demonstrate a working knowledge of preparing and performing destructive testing in accordance with government safety regulations, manufacturer s recommendations and approved industry standards with a focus of meeting or exceeding the testing requirements of the CSA or ASME Codes/Standards regarding weld quality. Learning Outcomes and Content: 3.1 Perform welds for destructive testing. [0/8] groove weld tests in position to identified procedures vee-groove with backing consumables E4918 positions required - flat (1G) - horizontal (2G) - vertical (3G) - overhead (4G) 3.2 Perform preparatory operations for destructive testing. [0/4] remove backing grind surface layout coupons cut coupons grind coupons 3.3 Perform destructive testing. [0/1] bend coupons - face and root bend - side bend 19

27 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 1 Subject Number: Reportable Subject: S0773 GAS TUNGSTEN ARC WELDING (GTAW) Total Hours: 45 Theory: 2 Practical: 43 Prerequisites: None Contents: S Set-Up Equipment For GTAW on Mild and Stainless Steels [2/3] S Perform Mild Steel Welds Using the GTAW Process [0/27] S Perform Stainless Steel Welds Using the GTAW Process [0/13] Evaluation & Testing: Practical projects related to the welding process procedure and position. Unit practical tests evaluated in accordance with applicable industrial weld quality acceptance criteria. Mark Distribution: Theory Practical Projects Notebook & Final Testing Testing Organizational Skills Assessment 0% 30% 70% 0% 0% Instructional and Delivery Strategies: Teacher-led practical skills training with demonstration and observation in welding shop. Reference Materials: Alberta ILM Welder Apprenticeship Modules 20

28 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 1 S SET-UP EQUIPMENT FOR GTAW ON MILD AND STAINLESS STEELS Total Hours: 5 Theory: 2 Practical: 3 Cross-Reference to Training Standard: , , , , , , , , General Learning Outcome: Upon successful completion, the apprentice is able to: Demonstrate a working knowledge of welding with the GTAW process. Learning Outcomes and Content: 1.1 Describe equipment set-up and the process of GTAW. [2/0] power source equipment shielding gas material type of welds and joints 1.2 Set-up equipment for a variety of GTAW applications. [0/3] material preparation and fit-up pre-weld cleaning methods position of welding equipment setup - current type and polarity - amperage - arc initiation method torch setup - collet and body - nozzle type and size - tungsten electrode type, size and preparation shielding gas - flow rate (imperial and metric) filler wire type, specification and diameter 21

29 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 1 S PERFORM MILD STEEL WELDS USING THE GTAW PROCESS Total Hours: 27 Theory: 0 Practical: 27 Cross-Reference to Training Standard: , , , , , , , , General Learning Outcome: Upon successful completion, the apprentice is able to: Perform groove and fillet welding on mild steel with the GTAW process in accordance with government safety regulations, manufacturer s recommendations and approved industry standards with a focus of meeting or exceeding the testing requirements of the CSA or ASME Codes/Standards regarding weld quality. Learning Outcomes and Content: 2.1 Perform welds using the GTAW process. [0/26] fillet weld tee joints - flat (1F) - horizontal (2F) fillet weld lap joints - horizontal (2F) fillet weld corner joints - flat (1F) - horizontal (2F) square butt groove welds - flat (1G) - horizontal (2G) - vertical (3G) 2.2 Perform post weld operations. [0/1] prepare completed welds for inspection visually inspect completed welds 22

30 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 1 S PERFORM STAINLESS STEEL WELDS USING THE GTAW PROCESS Total Hours: 13 Theory: 0 Practical: 13 Cross-Reference to Training Standard: , , , , , , , , General Learning Outcome: Upon successful completion, the apprentice is able to: Perform groove and fillet welding on stainless steel in accordance with government safety regulations, manufacturer s recommendations and approved industry standards with a focus of meeting or exceeding the testing requirements of the CSA or ASME Codes/Standards regarding weld quality. Learning Outcomes and Content: 3.1 Perform fillet and square groove welds on stainless steel with the GTAW process. [0/12] welding parameters shielding gas specification equipment set-up filler wire type and specification material preparation fillet welds - technique cup walking and freehand - horizontal (2F) - vertical (3F) Square groove welds (plate) - flat (1G) - horizontal (2G) 3.2 Perform post weld operations. [0/1] prepare completed welds for inspection visually inspect completed welds 23

31 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 1 Subject Number: Reportable Subject: S0774 GAS SHIELDED SEMI-AUTOMATIC WELDING Total Hours: 96 Theory: 5 Practical: 91 Prerequisites: None Content: S Fillet Welds with Gas Metal Arc Welding (GMAW) [2/21] S Groove Welds with Gas Metal Arc Welding (GMAW) [0/33] S Pulsed Arc Gas Metal Arc Welding (GMAW-P) [1/11] S Fillet Welds with Flux Cored Arc Welding (FCAW) [1/12] S Groove Welds with Flux Cored Arc Welding (FCAW) [1/14] Evaluation & Testing: Practical projects related to the welding process procedure and position. Unit practical tests evaluated in accordance with applicable industrial weld quality acceptance criteria. Mark Distribution: Theory Practical Projects Notebook & Final Testing Testing Organizational Skills Assessment 0% 30% 70% 0% 0% Instructional and Delivery Strategies: Teacher-led practical skills training with demonstration and observation in welding shop. Reference Materials: Alberta ILM Welder Apprenticeship Modules 24

32 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 1 S FILLET WELD WITH GAS METAL ARC WELDING (GMAW) Total Hours: 23 Theory: 2 Practical: 21 Cross-Reference to Training Standard: , , , General Learning Outcome: Upon successful completion, the apprentice is able to: Perform fillet welding with the GMAW process in accordance with government safety regulations, manufacturer s recommendations and approved industry standards with a focus of meeting or exceeding the testing requirements of the CSA or ASME Codes/Standards regarding weld quality. Learning Outcomes and Content: 1.1 Describe equipment set-up and the process of the GMAW. [1/0] power source wire feeder shielding gas and consumables technique type of welds & joints 1.2 Set-up and maintain equipment for a variety of GMAW applications. [0/2] consumables for the application wire type & specification - diameter shielding gas - changing shielding gas cylinders - adjusting gas flow rate - gas leak detection welding parameters - voltage - wire feed speed work lead connection wire feeders - drive roll tension - spool axle tension contact tip 25

33 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 1 nozzle configuration and sizes liner wear and restrictions 1.3. Perform fillet welding using the GMAW process on mild steel. [0/17] pre-cleaning and preparation modes of metal transfer - short circuit - spray joint types - lap joint - tee joint - corner joint positions - flat (1F) - horizontal (2F) - vertical (3F) - overhead (4F) applications - plate and sheet - structural shapes - structural shapes to plate 1.4 Perform post weld operations. [1/2] clean and finish welds to specifications visually inspect and evaluate finished welds 26

34 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 1 S GROOVE WELD WITH GAS METAL ARC WELDING (GMAW) Total Hours: 33 Theory: 0 Practical: 33 Cross-Reference to Training Standard: , , , General Learning Outcome: Upon successful completion, the apprentice is able to: Perform groove welding with the GMAW process in accordance with government safety regulations, manufacturer s recommendations and approved industry standards with a focus of meeting or exceeding the testing requirements of the CSA or ASME Codes/Standards regarding weld quality. Learning Outcomes and Content: 2.1 Prepare base metal for groove welding. [0/2] type of groove joint welding symbol type of metal backing requirements method of joint preparation surface finish joint opening placement of tacks preheat requirement 2.2 Perform groove welding on mild steel using the GMAW process. [0/12] pre-cleaning and preparation modes of metal transfer - short circuit - spray joints - single bevel groove with backing - single vee-groove positions - flat (1G) - horizontal (2G) - vertical (3G) 27

35 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 1 - overhead (4G) material - plate 2.3 Perform post weld operations. [0/1] clean and finish welds to specifications visually inspect and evaluate finished welds 2.4 Perform welds for destructive testing. [0/14] positions - flat (1G) - horizontal (2G) - vertical (3G) - overhead (4G) 2.5 Perform operations for destructive testing. [0/4] remove backing grind surfaces layout coupons cut coupons grind coupons bend tests - face and root bends - side bends 28

36 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 1 S PULSED ARC GAS METAL ARC WELDING (GMAW-P) Total Hours: 12 Theory: 1 Practical: 11 Cross-Reference to Training Standard: , , , General Learning Outcome: Upon successful completion, the apprentice is able to: Demonstrate a working knowledge of fillets and groove welds with the process. GMAW-P Learning Outcomes and Content: 3.1 Describe equipment set-up and the process of GMAW-P. [1/0] equipment - power source - wire feeder pulsing variables shielding gas technique material type of welds 3.2 Perform fillet and groove welds with the GMAW-P process on mild steel. [0/11] material - thin gauge fillet welds - flat (1F) - horizontal (2F) - vertical up (3F) - overhead (4F) groove welds - vertical (3G) 29

37 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 1 S FILLET WELD WITH FLUX CORED ARC WELDING (FCAW) Total Hours: 13 Theory: 1 Practical: 12 Cross-Reference to Training Standard: , , , General Learning Outcome: Upon successful completion, the apprentice is able to: Perform fillet welding with the FCAW process in accordance with government safety regulations, manufacturer s recommendations and approved industry standards with a focus of meeting or exceeding the testing requirements of the CSA or ASME Codes/Standards regarding weld quality. Learning Outcomes and Content: 4.1 Set up equipment for a variety of FCAW applications. [1/2] consumables for the application wire type and size - gas shielded - self-shielded shielding gas - changing shielding gas cylinders - adjusting gas flow rate - gas leak detection welding parameters - voltage - wire feed speed maintenance of equipment - wire feeders - drive rolls - spool axle tension - contact tip - gun nozzle - gun liner 4.2 Perform welding of mild steel using the FCAW process. [0/8] fillet welds lap joint tee joint 30

38 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 1 corner joint positions - flat (1F) - horizontal (2F) - vertical (3F) - overhead (4F) applications - plate - structural shapes - structural shapes to plate 4.3 Perform post weld operations. [0/2] clean and finish welds to specifications visually inspect and evaluate finished welds 31

39 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 1 S GROOVE WELD WITH FLUX CORED ARC WELDING (FCAW) Total Hours: 15 Theory: 1 Practical: 14 Cross-Reference to Training Standard: , , , General Learning Outcome: Upon successful completion, the apprentice is able to: Perform groove welding with the FCAW process in accordance with government safety regulations, manufacturer s recommendations and approved industry standards with a focus of meeting or exceeding the testing requirements of the CSA or ASME Codes/Standards regarding weld quality. Learning Outcomes and Content: 5.1 Prepare base metal for groove welding. [1/2] type of groove joint welding symbol backing requirements method of joint preparation joint opening placement of tacks 5.2 Perform groove welding on mild steel using the (FCAW) process. [0/7] single bevel with backing bar positions - flat (1G) - horizontal (2G) - vertical (3G) - overhead (4G) 5.3 Perform post weld operations. [0/1] clean and finish welds to specifications visually inspect and evaluate finished welds 5.4 Prepare welds for destructive testing. [0/2] positions - flat (1G) - horizontal (2G) 32

40 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 1 - vertical (3G) - overhead (4G) 5.5 Perform operations for destructive testing. [0/2] remove backing grind surfaces layout coupons cut and grind coupons side bend test 33

41 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 2 Pressure Systems Welder Level 2 PROGRAM SUMMARY OF REPORTABLE SUBJECTS Subject Number Reportable Subject Hours Total Hours Theory Hours Practical S0775 Codes for Pressure Welding S0776 Manual Pressure Welding S0777 Semi Automatic Pressure Welding S0778 Pressure Welding Procedures and Qualifications S0779 Specialized Pressure Welding Techniques Total

42 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 2 Subject Number: Reportable Subject: S0775 CODES FOR PRESSURE WELDING Duration in Hours: Total Hours: 30 Theory: 30 Practical: 0 Prerequisites: None Content: S ASME Boiler and Pressure Vessel Code [6/0] S Material Specifications [12/0] S Product Specifications [6/0] S Inspection Specifications [6/0] Evaluation & Testing: Assignments related to theory and appropriate application skills Final exam at end of term Periodic quizzes Mark Distribution: Theory Practical Projects Notebook & Final Testing Testing Organizational Skills Assessment 70% 0% 0% 0% 30% Instructional and Delivery Strategies: Lecture and assignment work with welding procedures and codes. Reference Materials: ASME Boiler and Pressure Vessel Code, Section II Part A, B and C, Section V, Section VIII and Section IX CSA Standard B51 - Boiler, Pressure Vessel and Pressure Piping Code Alberta ILM Welder Apprenticeship Module e Codes and Standards 35

43 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 2 S ASME BOILER AND PRESSURE VESSEL CODE Total Hours: 6 Theory: 6 Practical: 0 Cross-Reference to Training Standard: , , General Learning Outcome: Upon successful completion, the apprentice is able to: Describe the outline of the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (BPVC) as it relates to the welding of pressure system components. Learning Outcomes and Content: 1.1 Define the scope of the ASME BPVC. [2/0] Regulatory requirement for compliance to the ASME BPVC Sections of ASME BPVC relating to materials, design, fabrication, welding and inspection 1.2 Explain the application of the ASME BPVC in pressure systems. [2/0] Requirements for boilers, pressure vessels and nuclear components Requirements of the Canadian Standards Association (CSA) B51 Boiler, Pressure Vessel and Pressure Piping Code 1.3 Identify the function and role of various jurisdictions and inspectors for pressure welding. [2/0] Technical Standards and Safety Authority (TSSA) Customer inspectors In-plant inspection and monitoring 36

44 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 2 S MATERIAL SPECIFICATIONS Total Hours: 12 Theory: 12 Practical: 0 Cross-Reference to Training Standard: , , General Learning Outcome: Upon successful completion, the apprentice is able to: Select base and filler metals as specified on welding procedure documents and explain the numbering system and characteristics of the selected materials. Learning Outcomes and Content: 2.1 Select base metals as specified on the Welding Procedure Specification. [4/0] Ferrous metals in accordance with ASME BPVC Sect. II Part A Non-ferrous metals in accordance with ASME BPVC Sect. II Part B SA and SB material specifications and corresponding P numbers 2.2 Select welding filler metals as specified on the Welding Procedure Specification. [2/0] Correct size and with required approvals Designations in accordance with ASME BPVC Sect. II Part C Filler metal form - Electrode rod - Electrode wire - Filler rod 2.3 Describe the basis for various filler metal designations including F numbers. [6/0] SFA number Classification number F number A number 37

45 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 2 S PRODUCT SPECIFICATIONS Total Hours: 6 Theory: 6 Practical: 0 Cross-Reference to Training Standard: General Learning Outcome: Upon successful completion, the apprentice is able to: Describe welding requirements based on the type of pressure component and applicable code section. Learning Outcomes and Content: 3.1 Identify the applicable code section based on the type of pressure component. [3/0] Power boilers Sect. I Nuclear components Sect. III Pressure Vessels Sect. VIII Power and Process Piping - ASME B31 - CSA B Identify requirements specified in applicable construction code. [3/0] Material preparation Identifying welds with welder stamping Tapered transitions Specified sign-offs after various stages of construction Testing - Non-destructive testing - Hydrostatic testing 38

46 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 2 S INSPECTION SPECIFICATIONS Total Hours: 6 Theory: 6 Practical: 0 Cross-Reference to Training Standard: General Learning Outcome: Upon successful completion, the apprentice is able to: Describe inspection requirements based on applicable code sections. Learning Outcomes and Content: 4.1 Identify source of weld quality acceptance criteria. [2/0] Sect. I Sect. III Sect. VIII 4.2 Describe requirements for non-destructive testing as specified in ASME BPVC Sect. V. [2/0] visual inspection penetrant inspection magnetic particle inspection radiographic inspection ultrasonic inspection 4.3 Describe the different weld quality characteristics that are the basis for acceptance criteria. [2/0] Size, shape and reinforcement Properties - mechanical - chemical - maintaining essential variables Soundness - porosity - cracks - fusion defects - inclusions 39

47 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 2 Subject Number: Reportable Subject: S0776 MANUAL PRESSURE WELDING Total Hours: 96 Theory: 5 Practical: 91 Prerequisites: S0772, S0773 Content: S Cutting and Preparation [0/11] S Fit-Up and Assembly [2/9] S Shielded Metal Arc Welding (SMAW) [0/36] S Gas Tungsten Arc Welding (GMAW) [3/35] Evaluation & Testing: Practical projects related to the welding process procedure and position. Unit practical tests evaluated in accordance with applicable industrial weld quality acceptance criteria. Mark Distribution: Theory Practical Projects Notebook & Final Testing Testing Organizational Skills Assessment 5% 65% 0% 0% 30% Instructional and Delivery Strategies: Teacher-led practical skills training with demonstration and observation in welding shop. Reference Materials: Equipment manuals and practical welding exercises based on Welding Procedure Specifications. 40

48 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 2 S CUTTING AND PREPARATION Total Hours: 11 Theory: 0 Practical: 11 Cross-Reference to Training Standard: , General Learning Outcome: Upon successful completion, the apprentice is able to: Perform cutting and preparation of pressure vessel and pipe components to specifications. Learning Outcomes and Content: 1.1 Perform manual oxy-fuel cutting and bevelling on pipe. [0/3] Tip selection Oxyfuel pressures Straight cuts Bevels Finished bevel cuts 1.2 Perform mechanized oxy-fuel torch cutting and bevelling processes (pipe bevellers). [0/2] Pipe beveller set-up Oxyfuel pressures Cutting machine set-up Straight cuts Finished bevel cuts 1.3 Perform mechanized air powered bevelling on pipe. [0/2] Die selection Bevelling machine set-up finished bevel cuts 1.4 Perform finished bevelling by grinding. [0/2] Grinder size and type Grinding consumable Straight cuts Bevels 41

49 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 2 Bevel finishes 1.5 Perform plasma arc cutting and bevelling on pressure pipe. [0/2] Air pressure Amperage Straight cut - free hand method - drag cup method Bevels free hand method 42

50 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 2 S FIT-UP AND ASSEMBLY Total Hours: 11 Theory: 2 Practical: 9 Cross-Reference to Training Standard: General Learning Outcome: Upon successful completion, the apprentice is able to: Perform fit-up and assembly of pressure vessel and pipe components to specifications. Learning Outcomes and Content: 2.1 Identify material. [1/0] Component stamping Colour coding Heat numbers Mill test reports 2.2 Select pressure boundary components. [1/1] Pressure pipe schedules and sizes Pressure tube sizes and uses Pressure fittings - reducers - flanges - tee connections - Y connections - 45 elbows - 90 elbows - sock-o-lets - weld-o-lets - thread-o-lets 2.3 Assemble and tack weld SMAW pipe project. [0/5] Use wrap to lay out pipe Tee and butt connection - cut pipe with oxy-fuel or plasma arc process - root face prep - ensure acceptable mismatch 43

51 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 2 - fit components with correct gap - feather tack welds See Appendix A for SMAW pipe project drawing 2.4 Assemble and tack weld GTAW pipe project. [0/3] Use wrap to lay out pipe Socket and butt connection Cut pipe - chop saw - horizontal band saw - grinder (zip cut) Feather edge prep Ensure acceptable mismatch Pre-cleaned socket prep See Appendix B for GTAW pipe project drawing 44

52 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 2 S SHIELDED METAL ARC WELDING (SMAW) Total Hours: 36 Theory: 0 Practical: 36 Cross-Reference to Training Standard: , , , General Learning Outcome: Upon successful completion, the apprentice is able to: Perform SMAW welding on pressure vessel and pipe components in accordance with government safety regulations, manufacturer s recommendations and approved industry standards with a focus of meeting or exceeding the testing requirements of the CSA or ASME Codes/Standards regarding weld quality. Learning Outcomes and Content: 3.1 Perform welds on pipe using SMAW. [0/33] Use SMAW fitting project (from 2.3) Tee connection - weld root 5G position - prep for visual inspection - weld hot pass(es) (fill) - prep for visual inspection - weld cap pass to code specifications Butt weld - weld root 6G position - prep for visual inspection - weld hot pass(es) (fill) - prep for visual inspection - weld cap pass(es) to code specifications 3.2 Perform preparations for destructive bend testing. [0/2] Lay out and cut coupons Grind surfaces 3.3 Perform destructive testing on welds. [0/1] Visual inspection of coupons Destructive test welds - Face bends - Root bends 45

53 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 2 S GAS TUNGSTEN ARC WELDING (GTAW) Total Hours: 38 Theory: 3 Practical: 35 Cross-Reference to Training Standard: , , , General Learning Outcome: Upon successful completion, the apprentice is able to: Perform GTAW welding on pressure vessel and pipe components in accordance with government safety regulations, manufacturer s recommendations and approved industry standards with a focus of meeting or exceeding the testing requirements of the CSA or ASME Codes/Standards regarding weld quality. Learning Outcomes and Content: 4.1 Perform welds on pipe using GTAW root with SMAW fill and cap. [2/30] Use GTAW fitting project (from 2.2.4) Socket connection - weld root 5G position - prep for visual inspection - complete weld to code specifications - prep for visual inspection Butt weld - install purging caps - argon purge assembly - verify full purge - weld root 1/8 inch ER309L, 2G, 5G position - prep for visual inspection - weld hot pass(es) 3/32 inch E309L-16 - prep for visual inspection - weld cap pass(es) to code specifications 1/8 inch E309L Perform preparations for destructive bend testing. [0/2] Lay out butt weld coupons Cut coupons Grind surfaces 4.3 Perform destructive testing. [0/1] Visual inspection of coupons 46

54 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 2 Destructive test welds - root bends - face bends 4.4 Prepare socket weld for destructive testing. [0/1] Lay out pipe for saw cutting (cold cut) Saw cut socket assembly per drawing 4.5 Perform socket weld testing procedures. [1/1] Polish weld specimens Macro etch specimens Inspect for minimum 10% weld penetration (no inclusions) 47

55 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 2 Subject Number Reportable Subject: S0777 SEMI-AUTOMATIC PRESSURE WELDING Total Hours: 51 Theory: 3 Practical: 48 Prerequisites: S0774 Content: S Gas Metal Arc Welding (GMAW) [1/29] S Flux Cored Arc Welding (FCAW) [2/19] Evaluation & Testing: Practical projects related to the welding process procedure and position. Unit practical tests evaluated in accordance with applicable industrial weld quality acceptance criteria. Mark Distribution: Theory Practical Projects Notebook & Final Testing Testing Organizational Skills Assessment 5% 65% 0% 0% 30% Instructional and Delivery Strategies: Teacher-led practical skills training with demonstration and observation in welding shop. Reference Materials: Equipment manuals and practical welding exercises based on Welding Procedure Specifications. 48

56 PRESSURE SYSTEMS WELDER CURRICULUM STANDARD LEVEL 2 S GAS METAL ARC WELDING (GMAW) Total Hours: 30 Theory: 1 Practical: 29 Cross-Reference to Training Standard: , , , , , , , General Learning Outcome: Upon successful completion, the apprentice is able to: Perform GMAW welding in short-circuiting, spray-arc, and pulsed-spray transfer modes on pressure vessel and pipe components in accordance with government safety regulations, manufacturer s recommendations and approved industry standards with a focus of meeting or exceeding the testing requirements of the CSA or ASME Codes/Standards regarding weld quality. Learning Outcomes and Content: 1.1 Describe equipment set-up and the process of GMAW utilizing short circuit, spray transfer and pulsed methods typically used in the pressure systems industry. [1/0] Equipment Power source Parameter control devices Wire feeder Pulsing variables Shielding gas Consumables Technique Material Type of welds 1.2 Perform groove welds on pipe with the GMAW process on carbon steel and low alloy steel as determined by the WPS. [0/15] Groove welds - open root Positions - horizontal / vertical, (2G) / (5G) - all (6G) 49